Metalwokking process



Nov. 14, 1939.

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METALWORKING PROCESS driginal Filed May 16,-1932 16 Sheets-Sheet 14 I Clare/nu w Hwlztt l M Q .2 TO R ATTORNJ$ Nov. 14, 1939. c. w. HAZELETT METALWORKING PROCESS Original Filed May 16, 1932 16 Sheets-Sheet 16 1w Lyvro AT-roqwgg clqrznse, Y1: Hamlsztb ghnwm/ Reissued Nov. 14,1939

PATENT OFFICE 21,260 METALWOBKING Pnocass Clarence W. Hazelett, Greenwich, Conn, aseignor to Hazelett Metals, Inc., Greenwich, Coma, a corporation of Delaware Original No. 2,058,447, dated October 27, 1938,

Serial No. 611,603, May 16, 1932.

Application {or reissue October 26, 1938, Serial No. 237,115

'54 Claims. (01. 229-2001) This invention relates to metal products, and to methods of and apparatus for producing the same, and more particularly, to the forming of metal from a molten state, andto metal shapes and articles so formed, and has for an object the provision of new and improved methods, new and improved apparatus, and new and improved metal products, thereunto appertaining.

In the drawings accompanying this specification and forming a. part of this application, I

have shown, for purposes of illustration, several embodiments which my invention may assume, and in these drawings:

Figures 1 and 2 are together a diagrammatic side elevation of an embodiment of my invention.

Figure 3 is a vertical longitudinal sectional view of a. mechanism for feeding molten metal.

Figure 4 is a plan view of the feeding mechanism illustrated in Figure 3,

Figure 5 is a side elevation of another embodiment of metal feeding mechanism,

Figure 6 is a plan view of the feeding mechanism illustrated in Figurefi,

Figure 7 is a vertical sectional view of still another embodiment of metal feeding mechanism,

Figure 8 is a fragmentary plan of a rolling mechanism,

Figure 9 is a vertical sectionalview taken on the line 9--9 of Figure 8,

Figure 10 is a vertical sectional view of another embodiment of rolling mechanism,

Figure 11 is a view partly in plan and partly in horizontal section of still another embodiment of rolling mechanism,

Figure 12 is a transverse vertical sectional view taken on the line i2--l2 of Figure 11,

Figure 13 is a view partly in elevationand partly in longitudinal-section of a further embodiment of rolling mechanism,

Figure 14 is a transverse sectional view taken on the line ll-ll of Figure 13,

Figure 15 is a transverse sectional view taken on the line l5--i5 of Figure 13,

Figure 16 is a transverse sectional'view taken on the line lI-JG of Figure 13,

Figure 17 is a fragmentary plan view ,pf an end dam mechanism,

Figure 18 is a side mechanism illustrated in Figure 17,

Figure 19 is a fragmentary plan view illustrating another embodimentof end dam means,

Figure 20 is a vertical sectional view taken on the line 20-40 of Figure 19,

elevation of the end dam.

ofl igurem,

Figure 21 is a plan view of a diflerent embodiment of roll and end dam mechanism,

Figure 22 is a plan view of another embodiment of roll and end dam mechanism,

Figure 23 is a vertical sectional view taken on the line 23-23 of Figure 22,

Figure 24 is-a fragmentary plan view of another embodiment of roll and end dam mechanism,

Figure 25 is a vertical sectional view taken on the line 25-25 of Figure 24,

Figure 26 is a fragmentary plan view of another embodiment of roll and end darn mechanism,

Figure 27 is a vertical sectional view taken on the line 2l2| of Figure 26,

Figure 28 is a fragmentary plan view of another embodiment of roll and end dam mechanism,

Figure 29 is a'vertical sectional view taken on the line 29-28 of Figure 28,

Figure 30 is a view, partly in side elevation and partly in vertical longitudinal section, of another embodiment of roll and end dam mechanism,

. Figure 31 is an end elevation of the means illustrated in Figure 30,

Figure 32 is-a perspective view of parts of the end dam .mechanism illustrated in Figures 30 and 31,

Figure 33 is a fragmentary vertical section of a rolling and cooling means,

Figure 34 is a side elevation of another embodiment of rolling and cooling mechanism,

Figure 35 is a plain view of rolling mechanism particularly adapted for forming bars of angular cross-section,

Figure 36 is a plan view of rolling mechanism particularly adapted for forming bars of channel cross-section,

Figure 37 is a plan view of rolling mechanism particularly adapted for forming bars of I crosssection,

Figure 38 is a vertical sectional view through rolling mechanism having corrugated surfaces,

Figure 39 is a fragmentary vertical sectional view'of rolling mechanism, illustrating several stages of solidification of metal with respect thereto,

Figure 40 is a front elevation of an embodiment wherein the metal is supplied by a gate,

Figure 41 is a section parallel to the plane of Figure 40, on'the line 41- of Figure 42,

Figure 42 is a top plan view-of the embodin ent of Figure 40,

Figure 43 is a horizontal section, on the line 43,-" of Figure 41,

Figure 44 is a side elevation of the embodiment Figure 45 is a detail of the gate biasing and connecting means,

Figure 46 is a detail view showing means for heatlng'the rolls,

Figure 47 is a detail view showing means for cooling the rolls selectively,

Figure 48 is a view showing one form of suitable torque indicator,

Figure 49 is a diagrammatic representation of a driving motor for automatic control,

Figure 50 is a diagrammatic representation of alternative automatic control means,

Figure 51 is a reproduction of a micro-photograph of a strip of steel rolled according to my process, while Figure 52 is a reproduction of a micro-photo.- graph of the strip, after rerolling.

In Figures 1 and 2 I have shown a horizontal mill 5|! comprising a pair of horizontal rolls 5| and 52 mounted in juxtaposed parallel relation and backed by a pair of backing rolls 53. The rolls 5| and 52 are cooled, as by water delivered to the spaces between the rolls 5|, and 52 and the respective backing rolls 53, as by ducts 54 controlled by valves 55, and are shown as driven by a motor 55 connected to the rolls 5| and 52 by a connection indicated diagrammatically at Variable speed of rotation of the rolls 5| and 52, if desired, may be secured in any suitable manner, as by using for the motor 56 a variable speed motor, or by inserting in the drive 51 a variable speed device V of any suitable construction.

Mounted on the roll 5| are a pair of end dams 58 cooperating with the rolls 5| and 52 to define between the rolls 5|. and 52, above the points of tangency thereof, a space 59 for the reception of molten metal.

Mounted above the mill 55 is a reservoir 8|! adapted to receive molten metal from any suitable source (not shown), and to deliver this molten metal to the space 59 between the rolls 5| and 52. The rolls 5| and 52 being below the temperature of fusion of the metal, the metal solidifies contiguous the rolls 5| and 52, and the metal so solidified contiguous the rolls 5| and 52 is carried down to the bight of the rolls, and issues as the continuous strip S.

With apparatus of this type the characteristicsof the strip S depend at least in large part on the relation between the extent of the solidification contiguous the rolls 5| and 52 and the spacing between the rolls 5| and 52. With the solidibetween the rolls, but beyond that point there occurs this marked difference, that thereafter, by reason of the fact that the solidified metal delivered at the bight of the rolls is of greater thickness than the spacing of the rolls, the strip is definitely a'rolled strip.

I find, however, that the extent of solidification, and therefore, for any given spacing of the rolls 5| and 52, the extent of solidification relative to the spacing of the rolls, is a result of vari- -of cooling fluid supplied. to the rolls.

ous factors, including the nature of the metal itself, the temperature of the metal as delivered to the rolls, the length of the arc of contact of the metal with the rolls, the temperature of the rolls, and the speed of rotation of the rolls, and concurrently, that for any given metal, I can maintain any desired extent of solidification, and therefore, with any given spacing of the rolls, any desired extent of solidification relative to the spacing of the rolls, by maintaining constant the relation between the various factors. And that I can maintain this relation constant by controlling anyone or more of the factors, to compensate for variation in one or more other factors.

For example, with any given metal, I may maintain constant extent of solidification, and

with a given spacing of the rolls, constant extent of solidification relative to the spacing of the rolls, despite variation in other factors, by coordinate variation in the speed of rotation of the rolls, as by variation in the speed of the motor 55 itself, or by means of the variable speed device V. Or I may accomplish the result by coordinately varying the arc of contact of the metal with the rolls, as by varying the fiow of metal to the space 59 between the rolls, or by varying the eifective height of the end dams, to vary the vertical extent of the space 59. Or I may accomplish the result by coordinately varying the temperature of the metal, as by actual variation of the temperature of the metal as supplied, or by heating the metal in the space 59 in any suitable accomplish the result by coordinately. varying the temperature of the rolls, as by coordinately varying the cooling thereof, as, for example, by varying the valves 55 to vary the amount of cooling fiuid supplied by the ducts 54, or by varying the temperature of the cooling fiuid itself, as by intermixing steam and water in varying proportion. Or if the temperature of the cooling fluid is itself variable, I may maintain constant cooling of the rolls by coordinately varying the quantity And of course I may accomplish the maintenance of constant extent of solidification, and of constant extent of solidification relative to the spacing of the rolls, by any combination of coordinate variationsof the factors.

Considering the factors mentioned, the extent of solidification is increased by decrease in the speed of rotation of the rolls, by decrease in the temperature of the metal, by decrease in the roll temperature, and so far as I am now aware, by increase in the arc of contact of the metal with the rolls.

But however the control may be accomplished, coordination of the factors governing the extent of solidification is of extreme importance, since variation, even if small, will materially afie'ct the quality and characteristics of the product, and of course, if larger, may result in appreciable damage and destruction, either by the passage of metal through the rolls without solidification, or, in the ottfler direction, by over-solidification to an extent sufiicient to wreck the mill. Whereas by suitable coordination it is possible to obtain and continuously to maintain any desired condition, as, for example, solidification of the metal in a thickness somewhat greater than the spacing of the rolls, whereby the metal is rolled by the rolls, and the strip S is a rolled strip.

In Figures 1 and 2' I have shown subsequent processing which may be in part or in whole applicable to a strip 8 of any characteristics, but which is presented as particularly applicable to 9. rolled strip.

This comprises first a reducing chamber 8| mounted adjacent the mill 8'] for the passage of the strip S therethrough, and containing reducing,gases operative both to reduce any oxide existent on the surface of the strip and also, to prevent or diminish such formation of oxide subsequently.

Adjacent the chamber 8! is mounted a re-rolling mill 82, for re-rolling the strip, either to vary its characteristics or to vary its size, or both, as may be desired.

Beyond the re-rolling mill 82 the .strip 3 passes successively: through a normalizing furnace 88, for heat treating the strip; through a pickling tank 84, containing acid or other suitable solution for removing any oxide present on the surface of the strip; through a washing tank 85, for washing the strip S after the emergence thereof from the pickling tank 84; and through a leveler 88, for leveling out any irregularities in'the strip. The strip S is shown as then passing to a shear 81, to be cut into lengths, and then as passing in this form to a forming press 68, to be formed and shaped as desired. It will be understood, however, that these operations to some extent may be performed in an order other than that illustrated, and also, that any or all of these operations may be omitted, all as may be desired. It is to be noted, however, that such of these operations as are included may operate on the strip while the strip retains its original heat, and without any reheating.- A

In this connection it may be added, that the passage of the strip immediatelythrough the reducing chamber GI and the re-rolling mill 62, so that the strip reaches the re-rolling mill 82 before any oxide has formed in any surface cracks present in the strip S, is most effective to completely obliterate any trace of any such cracks,

as though such cracks had never existed.

From the foregoing, it will be apparent that by use of the apparatus described, metal from a molten state may be formed into a solid continuous strip, and treated and fabricated into a finished article, by a succession of instrumentalities operating continuously, while the metal still is hot and connected with the, parent body of molten metal in the space 58 between the rolls BI and 52.

In Figures 3 and 4 I have shown a detailed em bodiment of means for supplying the molten metal to the rolls, corresponding to the reservoir 8|! heretofore referred to, and comprising a reservoir 89, lined with fire brick to resist theaction of the molten metal, and mounted between the forward ends of a pair of arms III, the rear ends of which are flxed to a shaft ll journaled in a support 12. A rearwardly extending arm 18 is also fixed to the shaft ll atone end thereof, and is provided with an adjustable counterweight 14 for counterbalancing the weight of the reservoir 88 and of the metal contained therein. Molten metal is supplied to the reservoir 69 through a submerged outlet 15 provided in the bottom of a ladle 18, and the flow of metal through this opening may be controlled by means of a vertically reciprocable valve member 1'! carried at the lower end of a rod 828 operated in any suitable manner. The rear wall of the reservoir 88 may be inclined, as indicated at I8, to prevent -ing spout 88 and a removable cover 99.

the metal delivered to the reservoir 88 from contacting too forcibly therewith, and for distributing the metal transversely of the reservoir 68 and deflecting it in a forward direction. The forward end of the reservoir 88 is provided with a dam 18 having a serrated upper edge forming a series of notches through which the metal overflows to the space 88 between the rolls Bi and 88. By means of this particular construction, the metal supplied to the reservoir 89 from the ladle I8 is allowed to form a pool ill at the rear of the dam 18, where it may become quiescent if in an effervescent state, and where it becomes distributed in a'lateral direction.

This dam 18 may, however, be formed with a straight overflow edge if desired, and the molten metal may be caused to flow over the dam in a succession of waves'or surges. To this end the reservoir 88 is constructed to be periodically tilted by means of a link 88 pivotallyconnected. at its. upper end to the end of the arm 13 and provided at its lower end with an eccentric strap 84 engaging a constantly rotating eccentric 85. The successive tilting of the reservoir 88 by the eccentric causes the molten metal to flow over the dam I! in a relatively broad stream of substanmounted at its upper end, as indicated at 88, and

which may be adjusted toward and away from the reservoir 88 by means of an adjusting screw 88. The bailie 88 may be heated by a flame issu- 1 ing from a burner 88, in order to prevent both cracking of the battle by the metal or premature chilling of the metal by the baflie.

After 'passingthrough the dam 19, the molten metal impinges upon'the baffle 88, which reduces its velocity, and further, tends to spread the metal, so that it surely will be distributed uniformly throughout the length of the rolls 8| and 82. The baiile 88 also functions to deflect the metal downwardly into the pool at a point of greatest depth, so that it will not have a tendency to melt the metal which has become solidified along the surface of these rolls, an action which would tend to cause the metal to pass through the rolls before it has become solidified to the desired extent.

In Figures 5and 6 I have shown molten metal being supplied to a reservoir 92 from a pair of Bessemer converters, indicated diagrammatically at 98 and 94. These converters may be operated alternately, to obtain a substantially continuous supply of metal to the rolls. The molten metal from the converters 93 and 9 is delivered to a chute 95 having converging side walls, which in turn supplies the metal to the reservoir 92. If the metal delivered from the converters be in an effervescent state, it will give up at least a considerable part of its gases while traversing the chute 95 and the reservoir 92.

In Figure 1 there is shown an arrangement in which molten metal is delivered to a reservoir 98 directly from a top-pour ladle QI'having a pour- This ladle-is pivotally mounted adjacent its forward end, as indicated at I08, and may be tilted by means of a chain Ill secured to the rear end thereof. A baille I8! is disposed within the ladle 91 in spaced relation with. the bottom thereof, so that the molten metal passing to the spout 88 will flow downwardly beneath the baflie, thus excluding any'dross from the metal delivered to the reservoir 36.. A burner I04 is provided in the cover 99, to project a fiame in the vicinity of the metal flowing through the spout 88, in order to minimize oxidation and reduce eflervescence. In this particular embodiment the reservoir is fixedly mounted upon a bracket I05, and is enclosed within a housing I06 supplied with reducing gas provided to prevent oxidation of the metal being delivered to the rolls.

In Figures 8 and 9 I disclose rolling mechanism including rolls I01 and I08 corresponding to the rolls 5| and 52. when the apparatus is initially set in operation, it .is desirable that the forming rolls I01 and I08 occupy a position in which their surfaces are in engagement, so that the molten ,metal will not run downwardly therebetween before it has had time to become sufficiently solidified to emerge as a strip. To this end means are provided for yieldably urging the forming roll I08 toward the roll I01. In this particular construction, the roll I01 is Journaled in a fixed hearing I08, but the roll I08, and its associated backup roll IIO, are mounted in bearings III and H2 provided in a carriage I I3 mounted for horizontal adjustment in a slide H4. The bearing III of the roll I01 may be a half-bearing, as shown, so as to permit the roll I08 to be quickly and easily removed or assembled in position.

The inner end of the carriage H3 is provided with a recess II5 formed with longitudinally extending slots H6 and with a plate II1 secured thereto by means of screws I I8 and provided with a centrally disposed opening II! surrounded by an annular flange or collar I20. A spring III is interposed between the end of the slide H4 and the plate 1, and urges the carriage II3, together with the forming roll I08 and the associated back-up roll IIII, toward the fixed roll I01. Disposed within the recess H5 is an adjustable stop I22 provided with diametrically disposed key portions I23 for sliding engagement with the slots H6 and also with an internally screw threaded tubular member I24 which extends rearwardly through the opening H8 in the plate II1 for engagement by a screw I25 rotatably mounted in a bearing I26 provided in the end of the slide II 4 and maintained against displacement by means of a pair of arcuate collar members I21 secured to the inner face of the slide II4 for engagement with an annular groove I28 provided in the screw I25. The other end of the screw I25 is provided with a bevelled gear I29 which is adapted to be rotated by means of a bevelled pinion I30 fixed to one end of a shaft 333 provided with an operating handle 334 and journaled in a bearing 335 carried by a bracket 336 fixed to the side of the slide II4. A pointer I3I is secured to the end of the slide "4 for cooperation with a series of calibrations provided on the periphery of the bevelled gear I20.

When the apparatus is not in operation, and there'is no metal between the rolls I01 and I08, the spring I2I urges the roll I06 into engagement with the roll I01. As soon, however, as metal is introduced into the space between the converging upper portions of the rolls I01 and I08, and becomes solidified through contact .therewith, the rotation of the rolls I01 and I08 carries the solidified metal downwardly between the rolls, thus causing the roll I08 to recede against theaction of the spring I2I until the carriage II3 abuts the adjustable stop I22, which determines the amount of separation between replaced by a new shell.

the rolls I01 and I 08, and the thickness of the bar 'or strip of metal rolled thereby. This distance may be regulated, to roll metal 01' the thickness desired, by accurately adjusting the position or thestop I22, by means of the operating handle 334 connected to the pinion I30, and to the posi: tion indicated by the pointer I3I.

The rolls I01 and I08 may be provided with scrapers I32, for preventing the metal from sticking thereto, and for removing scale therefrom, and may be cooled by water sprayed thereon from pipes I33.

In Figure 10 there is shown another type of construction comprising forming rolls I34 each having an inner core I35 within an outer shell I36 01 an internal diameter considerably in excess of the outside diameter of the core I35. The

core I35 and shell I36 engage at the bight of the rolls I34, and, are provided with external and internal teeth I31 and I38, respectively, which intermesh at that point.

, The shells I36 are supported by rolls I33 and are cooled both externally'and internally by a cooling medium such as water or live steam, or a combination thereof, issuing from nozzles I40 and I located respectively outside the shell I36 and between the core I35 and shell I36, at a point diametrically opposite the point of tangency between the core I35 and the shell I36. The' flow of cooling fluid to the nozzles I40 and I H may be controlled by valves I42 provided in supply pipes I43, thus to vary the temperature or the rolls I34, to controilably affect solidification of the metal, as hereinbefore pointed out. By means of this construction the rolls I34 present substantially solid and unyielding surfaces to the metal being rolled, yet at the same time permit the shell to be cooled both internally and externally. It will be noted also that the shell, the part in actual contact with the metal, is relatively thin, as compared to the remainder of the roll, and consequently dissipates heat very quickly when subjected to the action of the cooling medium issuing from the nozzles I40 and HI, but presents what is in efiect a continuous and solid roll at the point of action, where it is subjected to strain. Also, in this construction the outer shells are relatively inexpensive, and may be quickly and easily removed for replacement or repairs, without disrupting the associated mechanism.

In Figures 11 and 12 there is shown a roll I52 comprising a solid steel core I44 having an outer shell I45 of cast iron. This provides a very inexpensive and eflicient construction, in that the roll is provided with a rough relatively tractive surface which may be chiseled off. when worn and In this construction the roll I46 is provided with a driving shaft I41 provided with a threaded portion I48, and an annular end dam I49 is secured tothe end of the roll I46 by means of screws I50, and is reinforced by means of. a back-up nut I5I threaded onto the portion I48 of the shaft I41. The outer periphery of the end dam I49 overlaps the ends or the adjacent cooperating roll I52, to provide a space between the rolls I46 and I52 adapted to receive the molten metal, and is provided with a plurality of peripheral teeth I63 formed with rounded extremities, but looming substantially to a knife edge. The teeth I53 cooperate with the end of the roll I52 to shear off any metal which may overflow over the top or the end dam, thus to prevent progressive freezing of metal from the end dam, outwardly into the space between the rolls, and the interference with operation .of the 

